11.2

Contents

Page

Removing pistons with conrods, stripping down and re-assembling

 ...................26

Removing piston with conrod  ............................................................................................................26
Dismantling piston .............................................................................................................................26
Checking piston dimensions  .............................................................................................................26
Assembling pistons  ...........................................................................................................................27
Checking cylinder dimensions ...........................................................................................................27
Removing and installing small-end bushing .......................................................................................27
Assembling pistons and conrods  ......................................................................................................28

Removing and installing crankshaft pinion and rotor flange

 ......................................28

Removing, dismantling and assembling combined oil-water pump

 ......................29

Removing pump  ................................................................................................................................29
Dismantling pump  .............................................................................................................................29
Removing slipring seal and shaft sealing ring  ....................................................................................30
Removing pressure relief valve  ..........................................................................................................30
Installing pressure relief valve ............................................................................................................30
Install the shaft sealing ring and slipring seal .....................................................................................30
Installing pump shaft and impeller  .....................................................................................................30

Removing output shaft

 ...............................................................................................................31

Removing oil sump ............................................................................................................................31
Removing oil filter ..............................................................................................................................31
Removing lower section of crankcase  ...............................................................................................31
Removing and installing oil level sight glass  ......................................................................................31

Stripping and assembling output shaft

 ...............................................................................32

Stripping down output shaft  ..............................................................................................................32
Stripping down tensioning gear  .........................................................................................................32
Assembling tensioning gear  ..............................................................................................................33
Installing damper  ...............................................................................................................................33

Assembling engine 

....................................................................................................................34

Installing output shaft

 ..................................................................................................................34

Assembling the crankcase  ................................................................................................................35
Installing oil mesh strainer  .................................................................................................................35
Installing oil filter ................................................................................................................................35
Installing oil sump ..............................................................................................................................35

Measuring crankshaft bearing play

 .......................................................................................36

Measuring radial play  ........................................................................................................................36
Measuring endplay  ............................................................................................................................37

Checking dimensions of crankshaft

 .....................................................................................37

Installing crankshaft

 .....................................................................................................................38

Installing piston with conrod

 ....................................................................................................39

Measuring big end bearing play

 .............................................................................................40

Installing big end bearing

 ..........................................................................................................40

Installing combined oil-water pump

 ......................................................................................41

Installing cylinder head

 ...............................................................................................................42

Installing camshafts

 .....................................................................................................................43